Part 3

Engine

Special Tool(s):

Material:

Crankshaft, Camshaft and Piston:

Front Cover, Rear Cover and Oil Components (Part 1):

Front Cover, Rear Cover and Oil Components (Part 2):

Cylinder Head and Rocker Arm Carrier:

Valve Cover:

Assembly (Steps 67-101)

67. If equipped, install the dual generator pulley and the 3 bolts.
^ Tighten to 47 Nm (35 ft. lbs.).

68. NOTE: Install a new O-ring seal on the coolant pump.

Install the coolant pump and the 4 bolts.
^ Tighten to 23 Nm (17 ft. lbs.).

69. Install the coolant pump pulley and the 4 bolts.
^ Tighten to 31 Nm (23 ft. lbs.).

70. Install the RH high-pressure oil rail-to-valve cover gasket.

71. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.

Install the gasket, the RH valve cover and the bolts and stud bolts.
^ Tighten to 9 Nm (80 inch lbs.).
72. Cover the LH cylinder head with an appropriate covering.

73. Install the 8 glow plugs.
^ Tighten to 19 Nm (14 ft. lbs.).

74. NOTE: Clean and apply clean engine oil to the O-ring seals.

Using the special tool, install the glow plug harness.

75. CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.

Install a new O-ring seal on the high-pressure oil pump.

76. Install the high-pressure tube assembly.

77. Install new lower O-ring seals.

78. Install the high-pressure pump and the bolts.
^ Tighten to 31 Nm (23 ft. lbs.).

79. Tighten the bolts for the high-pressure tube assembly.
^ Tighten to 11 Nm (8 ft. lbs.).

80. Install a new press-in-place gasket in the high-pressure pump cover.

81. Clean the cover mounting surface and apply sealer at the seams.

82. CAUTION: To prevent engine damage, the high-pressure oil pump cover must be firmly seated on the O-ring seal to prevent cracking the cover plate.

NOTE: Apply clean engine oil to the high-pressure oil pump O-ring seal prior to installing the high-pressure pump cover.

Install the high-pressure oil pump cover and the 8 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).

83. Using the special tool, install the injection pressure regulator (IPR) valve.
^ Tighten to 50 Nm (37 ft. lbs.).

84. If equipped, install the heat insulating wrap and fasten the snap.

85. Position the turbocharger heat shield and install the 3 bolts.
1 Tighten to 49 Nm (36 ft. lbs.).
2 Tighten to 11 Nm (8 ft. lbs.).

86. Install the oil pump inlet strainer.

87. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.

Install the gasket, the oil cooler assembly and the bolts.
^ Tighten to 22 Nm (16 ft. lbs.).

88. Install the gasket, the oil filter base and the bolts.
1 Tighten to 22 Nm (16 ft. lbs.).
2 Tighten to 10 Nm (89 inch lbs.).

89. Install the gasket, the exhaust gas recirculation (EGR) cooler coolant supply port cover and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).

90. Install a new O-ring seal in the oil filter base.

91. Install the oil filter adapter and the bolts.
^ Tighten to 15 Nm (11 ft. lbs.).

92. Install the accessory drive belt idler pulley and the bolt.
^ Tighten to 47 Nm (35 ft. lbs.).

93. If equipped, install the belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

94. NOTE: Install new sealing washers.

Install the LH cylinder head fuel tube.
^ Tighten to 38 Nm (28 ft. lbs.).

95. NOTE: Install a new O-ring seal on the thermostat.

Install the thermostat housing and the stud bolts.
^ Tighten to 23 Nm (17 ft. lbs.).

96. Position the fuel tube support bracket and install the nut.

97. Install the RH motor mount plate and the 4 bolts.
^ Tighten to 80 Nm (59 ft. lbs.).

98. Install the special tools.

99. Install the special tool.
100. Install the lifting crane and remove the engine from the engine stand.

101. Install the flexplate and tighten the new bolts in the sequence shown, in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 94 Nm (69 ft. lbs.).